Junctures between the uppers and outer soles of shoes



Nov. 8, 1960 D, SCALA 2,958,965

JUNCTURES BETWEEN THE.' UPPERS AND OUTER SOLES OF SHOES Filed April 2l, 1958 2 Sheets-Sheet l mmm'mw 36 l In \\\\m\\\rmV/// i INVENTOR.

52 JOSEPH D. SCALA ,y l I L P J 5, l,

NOV. 8, 1960 I 1 D, SCALA 2,958,965

JUNCTURES BETWEEN THE UPPERS AND OUTER SOLES OF SHOES Filed April 2l, 1958 2 Sheets-Sheet 2 0 f n lad 'ed 7 l nllgg.

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\\ ,A e l@ v Pfg/4 95 INVENTOR' JOSEPH D. SCALA .f -Qoe 5 m m Tomy 2,958,965 Patented Nov. 8, 1960 fr CC JUNCTURES BETWEEN THE UPPERS AND OUTER SOLES OF SHOES Joseph D. Scala, 261 Oak St., Stroudsburg, Pa. Filed Apr. 21, 1958, 'Sel'. No. 729,752 1 Claim. (Cl. 36-16) This invention relates generally to footwear, and more particularly has reference to an improved shoe construction, designed to provide maximum protection from the wtather, at the juncture between the upper and the so e.

In accordance with the present invention, there is a generally improved means for connecting lan outer sole to an upper and to an insole. T-he invention, in this connection, includes means for effecting connectionof the upper, insole, and outer sole to a midsole if desired.

Considerable diculty is experienced, in shoe manufacture, in providing a junction between the sole assembly and upper, which will be fully weatherproof, that is, will resist the entrance of moisture, while at the same time being strong and fully resistant t'o separation of the upper from the sole portion of the footwear.

One object of the present invention, accordingly, is to provide a construction of the character described above which will include an outer s ole of rubber, plastic composition, or any of various synthetic, resilient, moldable materials suitable for use as an outer sole, said outer sole being formed with a welt that provides a full sealing action at the location of the mentioned joint between the upper and the sole means of the shoe.

Another object is to provide a shoe of the character stated wherein the peripheral stitching normally used for connecting an upper to a sole assembly will be completely concealed from view, and will be fully, sealably protected by the sole against the entrance of moisture, the parting of stitches, or other undesirable characteristics noted in conventional shoe construction.

A further object of importance is to provide a novel means for completely embedding the stitchingin the outer sole, said means including a moldable bottom section of the outer sole which is vulcanized to a stitched upper section in such a manner as to completely recess the stitching while at the same time flowing upwardly about the periphery of the upper in a manner to effect the mentioned sealing action at the welt of the shoe.

Yet another object of importance is to so form the molded outer sole as to not only accomplish the desired sealing action hereinbefore mentioned, but also, provide a very attractive welt that will measurably increase the saleability of the shoe, the invention being such as to permit molding of the welt in any of a large variety of shapes.

Yet another object is to provide a shoe construction which will have all the desirable characteristics noted above, while still being capable of manufacture at a very low cost, considering the benefits to be obtained through the use thereof.

For further `comprehension of the invention, and of the objects and advantages thereof, reference will be had to the following description and accompanying drawings, and to the appended claim in which the various novel features of the invention are forth.

more particularly set l In the accompanying drawings forming a material part of this disclosure:

Fig. 1 is a view of a shoe construction according to the present invention, the shoe being illustrated in side elevation, part of the shoe being in longitudinal section and another part being broken away.

Fig. 2 is an enlarged, sectional view substantially on line 2-2 of Fig. 1.

Fig. 3 is a sectional View on the same scale as Fig. 2, taken on the same cutting plane as Fig. 2, showing the shoe during an intermediate stage of manufacture.

Fig. 4 is an enlarged, detail sectional view like Fig. 2, of a modified form of the invention, Showing the shoe in its completed state.

Fig. 5 is a view like Fig. 2 showing a modified construction.

Fig. 6 is a View like Fig. 2 showing another modification.

Fig. 7 is an exploded, detail sectional view through the peripheral portion of another modification, during an intermediate stage of manufacture.

Fig. 8 is a detail sectional View of the form of the invention shown in Fig. 7, in its completed condition.

Fig. 9 is a View like Fig. 7 showing still another modiiication, the dotted lines indicating the sole in the completed condition of the shoe.

Fig. 10 is a view like Fig. 7, showing still another modification.

Fig. 1l is a detail sectional View of the form shown in Fig. 10, in its completed condition.

Fig. 12 is a fragmentary longitudinal sectional View of the heel portion of the shoe shown in Fig. 9, at an intermediate stage of manufacture.

Fig. 13 is a View like Fig. 12 showing a further modified form of shoe construction.

Fig. 14 is a View like Fig. 10, showing still another modification.

Fig. 15 shows a modified form of welt.

Referring to the drawings in detail, in the form of the invention shown in Fig. l, a shoe has been generally designated at 10. In the illustrated example, the shoe has an upper 12 provided with a strap 14.

It will be understood, in this connection, that in actuality, the particular type of shoe can be varied, without departure from the spirit of the invention. The invention lies in the manner of connecting the upper and the sole assembly of the shoe, and obviously, the upper can be any of a large variety of different types.

In any event, in the form of the invention shown in Figs. 1-3, the upper 12 has an edge portion 16 which, throughout the periphery of the upper, is turned inwardly as shown clearly in Fig. l.

The inwardly turned edge portion 16 of the upper 12 is disposed in underlying relation to the peripheral portion of a sock lining or insole 18, with said edge portion 16 being in overlying relation to the peripheral portion of an upper section 20 of an outer sole generally designated 22.

As shown in Fig. 2, the underside of the edge portion 16 can be roughened as at 24, to provide maximum adherence to the upper lamination 20 of the outer sole. Further, a ller piece 26 is interposed between the insole 18 and the upper section 20, as shown in Figs. 2 and 3, so as to fill the space therebetween, said filler piece being coplanar with and being of a thickness substantially duplicating that of the inwardly turned edge portion 16 of the upper 12.

After the parts have been -assembled as shown in Fig. 2, stitching 28 is applied, extending continuously through the full periphery of the upper. Stitching 28 is extended through the marginal portion of the insole 18, the edge portion 16, and the marginal portion of the upper section 2! of the outer sole 22.

Application of the stitching is handled by conventional stitching mechanisms already known in the shoe manufacturing arts. The depth of the stitching is controlled by the mechanism in such a manner as to impart selected tension to the stitching, whereby the stitching compresses the upper lamination or section 20, pulling upwardly on the underside of said lamination in such a manner as to form a downwardly opening groove 30 therein as best shown in Figs. 2 and 3. In other words, in the area between the groove 30 and the top surface of the lamination 20, the material of the lamination 20 will be compressed at the location 32 shown in Fig. 2.

It will be understood that suitable adhesive could be applied to opposite faces of the ller piece 26, or to one face thereof, to assure its adherence to adjacent, contacting portions of the insole 18 or upper lamination 20 of the outer sole 22.

After the process has been carried through the above designated steps, the upper lamination 20 is positioned over a bottom lamination 34 of outer sole 22 (see Fig. 3), within a mold generally designated at 36. The mold has only been shown diagrammatically, and can be any of various conventional molds known in the art.

In addition, a separate thickness of sole material can be applied at the heel of the shoe, said separate thickness being caused to bond integrally with the lower lamination 34 within the mold 36, `and being designated at 38 in Fig. 1. Alternatively, the heel part 38 can be an integral part of the lower lamination 34, before insertion of the lamination 34 within the mold. The mold, in other words, will have molding surfaces of any ydesired shape, designed to impart a selected roughness or tread pattern to the underside of the outer sole 22, and designed, further, to impart any desired heel formation on the rear end of the outer sole.

In any event, the various components of the shoe are inserted in a mold as shown in Fig. 3, and by a vulcanizing action, the lower lamination 34 is caused to bond integrally to the upper lamination 20, so that in the completed shoe there is a unitary or integral outer sole as shown in Fig. 1. The result is that the stitching 28 will be completely embedded within the outer sole, again as shown in Fig. l, said stitching opening inside the upper rather than exteriorly thereof at the top of the row of stitching.

The mold has a rim portion 40, which can have a molding surface 42 of any desired configuration, that shown in Fig. 3 being merely one example of the molding surface of the rim portion. The curved surface of the rim portion 40 during fabrication causes the ma* terial of the lower lamination 34 to flow upwardly about the periphery of the upper lamination 20, into sealing contact with the outer surface of the upper 12. The portion of the lower lamination 34 that projects outwardly from the upper, and that is in sealable Contact with said upper is molded to the desired welt shape by the molding surface 42, so that in the example given in Fig. 1, there is deiined a beaded or ribbed welt 44 on the outer sole. Any desired texture can be imparted by a molding action to the outer surface of the welt, so as to increase the attractiveness of the shoe.

It will be seen that the completed shoe, shown in Fig. l, has a thick outer sole of rubber, or of any suitable composition material already known in the art, which outer sole is sealably engaged with the periphery of the upper, yand completely encloses the stitching of any equivalent connection of the upper to the various portions of the sole. A very strong connection is thus produced at the juncture between the upper and the sole assembly, said assembly being generally designated at 45 and constituting all the sole members, including the two laminations of the outer sole, and the insole 18. The sealed, weatherproof joint thus produced is very strong, provides full protection against the admission of moisture, and at the same time imparts a very attractive appearance to the shoe, which appearance is capable of being ininitely varied, as will be obvious from the fact that the variation is readily achieved merely by the provision of selected molding surfaces on the mold 36.

In Fig. 4, there is shown a modified construction wherein the shoe has been generally designated at 46 and includes an outer sole assembly generally designated at 418.

Apart from having a high, narrow welt or bead 44B instead of the relatively low, thick welt or bead 44 of Fig. 1, the construction of Fig. 4 is identical to that of the rst form.

In Fig. 5, there is shown a modied construction generally designated at 50. This includes certain components identical to those of the first forms, that is, the upper 12 is connected by stitching 28 to an insole 18, the stitching extending through the inwardly turned edge portion 16 of the upper, the shoe also including the ller piece 26.

In this form of the invention, the outer sole 22b is formed identically to that of the rst form, and differs only from the rst form in that the underside of the completed outer sole has deep grooves 52. These provide a desired tread pattern on the underside of the sole, and of course this pattern can be varied as desired. These grooves furthermore provide a resiliency that is very desirable in this type of shoe. Further, in this form, there is a bead 44b which is of approximately circular cross section.

It will be understood that any of the various peripheral beads shown in Figs. 1-5 can be used with any desired tread pattern on the sole, etc., that is, the pattern 52 can be used in the forms of the invention shown in Figs. 1 and 4, and the rib shown in Fig. 1 could be used on the form of the invention shown in Fig. 5, etc.

In Fig. 6, by way of example, there is shown another modification wherein the shoe, generally designated 54, is identical in all respects to those previously described herein, except that the outer sole 22c has a tread pattern in the form of deep, arcuate recesses 52c Further, in this form of the invention there is a sealing rib 44 in the form of a flange with a round outer end which in cross section appears as shown in Fig. 6. Again, the tread pattern can be used in any of the forms previously described, and this is true also of the sealing flange 44.

In all forms of the invention so far described, the upper 12 has its edge portion 16 turned inwardly. This is one type of cement down construction, with which the invention can be used to particular advantage. In all forms, of course, there is the common characteristic wherein the outer sole comprises an upper lamination through which the stitches 28 extend, and a lower 1amination which bonds integrally to the outer sole in a mold, and ilows around the outer sole into sealing contact with the upper.

In the form of the invention shown in Figs. 7 and 8, the upper of the shoe 56 has been designated at 12d, and has an outwardly turned peripheral portion 16d disposed in overlying relation to the edge portion of an insole 18d disposed in overlying relation to the edge portion of an insole 18d disposed in overlying relation to the edge portion of an insole 18d which in turn overlies the upper lamination 20d of an outer sole. through the superposed thicknesses of the edge portion 16d, insole 18d, and upper lamination 20d. In this connection, as will be noted from Fig. 7, the marginal part of the upper lamination 20d projects outwardly beyond the registered outer edges of the insole 18d and of the upper.

After the upper lamination 20d has been connected to the upper and insole by the stitching, the shoe `is placedv in a mold in the same manner as shown in Fig. 3, above' Stitching 28d extends' a bottom lamination 34d, the edge of which is registered with that of the upper lamination. These laminations are vulcanized together, and flow upwardly within the mold as shown in Fig. 8, and then flow inwardly in overlying relation to the edge portion 16d, to contact the side wall of the upper 12d. Thus, the outer sole is molded with an upwardly and inwardly directed peripheral ange SS disposed in overlying, enclosing relation to the conuected insole and upper, so as to completely enclose the stitching 28d and provide a fully weatherproof connection between the outer sole and the upper. This is a stitch down type of shoe construction, without a welt.

Of course, as in the other forms of the invention, the exposed surfaces of the outer sole can be provided with any desired pattern, ribbing, roughening, etc., calculated to improve the usefulness and the attractiveness of the shoe.

In Fig. 9 there is shown another modification wherein the shoe has been designated at 62 and is of the stitch down type. In this form of the invention the construction is identical to that of Figs. 7 and 8, with the exception that in addition to the insole or sock lining 18d, there is provided a midsole 64. This is interposed between the upper lamination 20d of the outer sole and the sock lining or insole 18d, and the edge of the midsole registers with that of the insole. Stitching 28d in this instance extends directly through the midsole.

In Figs. 10 and ll there is shown another modification. This differs from all the constructions previously illustrated and described in that it is a stitch down type with a stitched down welt as distinguished from the weltless constructions shown in Figs. 1-9, respectively.

The principles of the invention remain the same, however, in the form of the invention shown in Figs. l0 and 11. As will be noted, the shoe 66 in this form has certain components which are identical to those of Figs. 7 and 8, that is, an upper 12d having an outwardly turned edge portion 16d. In this form of the invention, the edge portion 16d is in overlying, registered relation with the insole 18d, exactly as in Fig. 7. However, in addition to the stitching 28d extending through these components, there is provided an inner row of stitching 68, which extends only through the portion 16d and insole 18d.

Referring to Fig. l0, a leather welting 70 is in overlying relation to the edge portion 16d, and projects laterally outwardly beyond the outside edge of the portion 16d. The upper lamination 20d of the outer sole has its edge in registration with the outside edge of the welting 70, and the stitching 28d extends not only through the upper and through the insole, but also through the welting and upper lamination 20d.

When the shoe is placed in the mold above a lower lamination 3:4d of the outer sole, the lower lamination bonds by vulcanizing action to the upper lamination 20d, and the material of the outer sole flows upwardly as at 72, forming a peripheral flange which completely bounds and is in sealing contact with the joint between the edge portion 16d and insole 18d. Further, flange 72 bonds to the underside of the welting 70 so as to provide a full sealing action, while at the same time producing a shoe of attractive appearance.

In Fig. l2 the heel portion of a shoe 74 is illustrated, and in actuality, this shoe is quite similar to those previously described, having an upper 12d, insole 18d, and a midsole 64. The outer sole includes the integrally joined upper and lower laminations 26d, 34d, respectively.

In this form of the invention, there is provided a separate heel lamination 76 which is in underlying relation to the rear end of the lower lamination 34d. During the vulcanizing action, the heel portion 76 bonds integrally to the lower lamination 34d. In the form shown in Fig. 13, the heel construction is similar to Fig. 12, and in addition may be formed with deep recesses 80. These recesses or holes may take any desired construction and shape. A liner 78 is also provided in this form of the invention and is shown in Fig. 12, but could -be included in any of the various other forms illustrated and described herilLY r Y The material of the heel portion 76 flows upwardly as at 82, forming an inwardly directed flange 84 overlying the edge portion of the upper.

Fig. 14 illustrated a fragment of a shoe made in accordance with a so-called California slip-last process. The shoe is designated by the Vnumeral and comprises an upper'12e, a'sock lining or insole 18e and a filler 26e. The outer sole 20,e is formed of special rubber compound for vulcanizing. In ythis form a leather welt 91 is stitched down directly onto the rubber of the outer sole 20e by stitching 92, and the insole 18e, upper 12e and extension 93 of the welt 91 are secured together by slip-last stitching 94.

The welt 91 may be shaped and constructed with a bead 95 contacting the side of the upper 12e as shown in Fig. l5 or the welt may be of any other desired shape.

It Will be understood that the grooves, holes, recesses and the like formed in the outer soles and heels of the various forms of the invention may take any desirable shape or form. This is an important feature of the construction as it assists in curing the rubber, reduces the time needed to cure the rubber, makes the sole lighter, skid proof and more flexible.

In all forms of the invention, there is a common characteristic wherein stitching extends through the edge portion of an upper and through one or more inner soles, while extending also through the upper lamination of an outer sole. The invention, in all forms, has the further characteristic wherein a lower lamination of the outer sole is vulcanized to the upper lamination so as to become integral therewith, the material of the outer sole at the sarne time fiowing upwardly into sealing relation to the connected upper and insole, while at the same time deeply embedding or recessing the stitching within the outer sole well upwardly from the bottom surface of the completed outer sole.

In all forms of shoe constructions, the outer sole may be made with one or more laminations depending upon the thickness of the sole desired, before vulcanizing.

The invention7 it has been found, has very desirable characteristics in respect to the weatherproofing of shoes, and in respect to providing attractive, strongly made footwear the design of which is capable of almost infinite variation, according to the desires of the particular manufacturers.

While I have illustrated and described the preferred embodiments of my invention, it is to be understood that I do not limit myself to the precise constructions herein disclosed and that various changes and modifications may be made within the scope of the invention as defined in the appended claim.

Having thus described my invention, what I claim as new and desire to secure by United States Letters Patent 1s:

A shoe construction comprising an upper, at least one inner sole, an outer sole, a heel, and a connecting means joining the upper to the inner sole, said outer sole being of a moldable material and including a peripheral portion about the joint between the upper and the inner sole, said connecting means comprising stitching extending through the upper and inner sole, and extending into the outer sole, said `stitching wholly embedded at its lower side within the outer sole, said stitching extended in the outer sole through the upper part thereof, the upper having an edge portion projecting laterally outwardly from the side wall of the upper and constituting the part of the upper through which said stitching extends, the outer sole having a peripheral flange of inverted L-shape in cross section disposed in embracing, overlying relation to the edge portion of the upper and the marginal part of the inner sole, said heel formed of moldable material and having a plurality of spaced deep recesses intersecting the vthread surface thereof whereby the heel is made more flexible.

References Cted'in the le of this patent UNITED STATES PATENTS FOREIGN PATENTS Great Britain May 17, 1923 8 VGreat Britain .Tuly 12, 1923 Great Britain June 19, 1924 Great Britain Sept. 22, 1927 Great Britain Mar. 20, 1930 France Dec. 28, 1931 France Dec. 19, 1951 France Mar. 26, 1952 France July 15, 1953 France June 30, 1954 Italy Aug. 25, 1953 Italy Dec. 23, 1954 Germany Jan. 8, 1953 Germany Oct. 11, 1954 Afu... 

